Electrochemical cell devices and methods of manufacturing

Abstract

Electrochemical cells and methods for their production are provided. In particular, multi-well assay plates including multi-electrode wells are provided. The multi-electrode wells contain multiple electrodes that are electrically isolated from one another, permitting the various electrodes of the various wells to be addressed in any suitable combination.

The invention claimed is: 
     
         1 . A multi-well assay plate including:
 a top plate having top plate opening defining wells of the multi-well assay plate arranged in a well pattern, each well being defined by a well area;   a base plate including a substrate having a top surface and a bottom surface, the top surface being mated to the top plate;   a plurality of well electrode structures, each of the plurality of well electrode structures including: an electrode grouping patterned on the top surface and having an auxiliary electrode and a plurality of working electrodes electrically isolated from the auxiliary electrode and a remainder of the plurality of working electrodes; and   an electrode contact grouping patterned on the bottom surface corresponding to the electrode grouping and including a plurality of electrode contacts including a plurality of working electrode contacts electrically connected to corresponding working electrodes and an auxiliary electrode contact electrically connected to the auxiliary electrode, wherein:   the top surface further includes an adhesive layer corresponding to the well pattern on the top surface, wherein the well areas are free of adhesive,   the electrode grouping is disposed within the well area and the electrode contact grouping is disposed outside of the well area,   each of the plurality of well electrode structures further includes a via grouping including a plurality of vias electrically connected to the plurality of electrode contacts and passing through the substrate, and   each of the plurality of electrode contacts includes a first electrically conductive layer extending at least approximately 0.015 inches from a corresponding one of the plurality of vias, and a second electrically conductive layer extending at least approximately 0.0008 inches from the first electrically conductive layer.   
     
     
         2 . The plate of  claim 1 , wherein each working electrode of a selected electrode grouping is configured to be electrically energized in isolation from electrical energization of remaining working electrodes of the plurality of working electrodes of the selected electrode grouping. 
     
     
         3 . The plate of  claim 1 , wherein multiple working electrodes of a selected electrode grouping are configured to be separately electrically energized. 
     
     
         4 . The plate of  claim 1 , wherein each well electrode structure is electrically isolated from remaining ones of the plurality of well electrode structures. 
     
     
         5 . The plate of  claim 1 , wherein the plurality of vias are each disposed approximately 0.019 inches outside of the well areas. 
     
     
         6 . The plate of  claim 1 , wherein the auxiliary electrode includes Ag/AgCl. 
     
     
         7 . The plate of  claim 1 , wherein each of the plurality of well electrode structures further includes an electrode trace grouping including a plurality of electrical traces patterned on the top surface and electrically connecting the plurality of vias to the electrode grouping. 
     
     
         8 . The plate of  claim 7 , wherein the plurality of vias includes two vias connecting each of the plurality of electrode contacts with each of the plurality of electrode traces. 
     
     
         9 . The plate of  claim 7 , wherein the plurality of electrical traces provide electrical connection between the electrode contact grouping arranged outside of the well area to the electrode grouping arranged inside of the well area. 
     
     
         10 . The plate of  claim 1 , wherein a plurality of electrode traces each include:
 a via contact spot in electrical communication with a corresponding one of the plurality of vias outside the well area and extending at least approximately 0.015 inches from a corresponding one of the plurality of vias, an electrical bridge extending from the via contact spot into the well area, and an electrode contact spot connected to the electrical bridge inside the well area.   
     
     
         11 . The plate of  claim 10 , wherein the plurality of electrode traces each include:
 a first electrically conductive layer, and   a second electrically conductive layer extending at least approximately 0.002 inches beyond the first electrically conductive layer, and wherein:   in the first electrically conductive layer, each of the plurality of electrode traces is disposed at least approximately 0.013 inches away from a remainder of the plurality of electrode traces, and in the second electrically conductive layer, each of the plurality of electrode traces is disposed at least approximately 0.010 inches away from the remainder of the plurality of electrode traces.   
     
     
         12 . The plate of  claim 10 , wherein the auxiliary electrode is disposed at an approximate center of the well area, and the working electrodes are arranged in a circle approximately equidistant from the auxiliary electrode. 
     
     
         13 . The plate of  claim 12 , wherein the working electrodes are separated from each other in the circle by a plurality of working electrode spacings, and at least one of the plurality of working electrode spacings is sized to permit disposition therein of an auxiliary electrode trace of the plurality of electrode traces connecting the auxiliary electrode to the auxiliary electrode contact. 
     
     
         14 . The plate of  claim 13 , wherein the auxiliary electrode includes a third electrically conductive layer extending at least approximately 0.008 inches past the electrode contact spot corresponding to the auxiliary electrode. 
     
     
         15 . The plate of  claim 13 , wherein the top surface of the substrate further includes a first insulating layer disposed in a pattern that exposes the electrode grouping of each of the plurality of electrode well structures and covers a remainder of the top surface of the substrate. 
     
     
         16 . The plate of  claim 13 , wherein the plurality of working electrodes each include a fourth conductive layer disposed over the electrode contact spot associated with a corresponding working electrode. 
     
     
         17 . The plate of  claim 16 , wherein each of the plurality of working electrodes are disposed at least approximately 0.0014 inches away from the remainder of the plurality of working electrodes. 
     
     
         18 . An electrochemical cell for performing electrochemical analysis, the electrochemical cell being formed on a base plate having a top surface and a bottom surface, the electrochemical cell including:
 a plurality of working electrode zones disposed, and defining a pattern, on the top surface of the base plate;   at least one auxiliary electrode disposed on the top surface, wherein each of the plurality of working electrode zones are electrically isolated from one another and from the auxiliary electrode; and   an electrode contact grouping patterned on the bottom surface corresponding to the plurality of working electrode zones and including a plurality of electrode contacts including a plurality of working electrode contacts electrically connected to corresponding working electrode zones and an auxiliary electrode contact electrically connected to the auxiliary electrode, wherein:   the top surface further includes an adhesive layer surrounding the plurality of working electrode zones and defining an adhesive free well area on the top surface,   the working electrode zones are disposed within the well area and the electrode contact grouping is disposed outside of the well area,   the electrochemical cell further includes a plurality of vias electrically connected to the plurality of electrode contacts and passing through the base plate, and   each of the plurality of electrode contacts includes a first electrically conductive layer extending at least approximately 0.015 inches from a corresponding one of the plurality of vias, and a second electrically conductive layer extending at least approximately 0.0008 inches from the first electrically conductive layer.   
     
     
         19 . A multi-well assay plate including:
 a top plate having top plate opening defining wells of the multi-well assay plate arranged in a well pattern, each well being defined by a well area;   a base plate including a substrate having a top surface and a bottom surface, the top surface being mated to the top plate;   a plurality of well electrode structures, each of the plurality of well electrode structures including: an electrode grouping patterned on the top surface and having an auxiliary electrode and a plurality of working electrodes electrically isolated from the auxiliary electrode and a remainder of the plurality of working electrodes; and   an electrode contact grouping patterned on the bottom surface corresponding to the electrode grouping and including a plurality of electrode contacts including a plurality of working electrode contacts electrically connected to corresponding working electrodes and an auxiliary electrode contact electrically connected to the auxiliary electrode, wherein:   the top surface further includes an adhesive layer corresponding to the well pattern on the top surface, wherein the well areas are free of adhesive,   the electrode grouping is disposed within the well area and the electrode contact grouping is disposed outside of the well area,   each of the plurality of well electrode structures further includes a via grouping including a plurality of vias electrically connected to the plurality of electrode contacts and passing through the substrate and an electrode trace grouping including a plurality of electrical traces patterned on the top surface and electrically connecting the plurality of vias to the electrode grouping,   the plurality of electrode traces each include:
 a via contact spot in electrical communication with a corresponding one of the plurality of vias outside the well area and extending at least approximately 0.015 inches from a corresponding one of the plurality of vias, an electrical bridge extending from the via contact spot into the well area, 
 an electrode contact spot connected to the electrical bridge inside the well area, 
 a first electrically conductive layer within which each of the plurality of electrode traces is disposed at least approximately 0.013 inches away from a remainder of the plurality of electrode traces 
 a second electrically conductive layer extending at least approximately 0.002 inches beyond the first electrically conductive layer and within which each of the plurality of electrode traces is disposed at least approximately 0.010 inches away from the remainder of the plurality of electrode traces. 
   
     
     
         20 . The plate of  claim 19 , wherein each working electrode of a selected electrode grouping is configured to be electrically energized in isolation from electrical energization of remaining working electrodes of the plurality of working electrodes of the selected electrode grouping. 
     
     
         21 . The plate of  claim 19 , wherein multiple working electrodes of a selected electrode grouping are configured to be separately electrically energized. 
     
     
         22 . The plate of  claim 19 , wherein each well electrode structure is electrically isolated from remaining ones of the plurality of well electrode structures. 
     
     
         23 . The plate of  claim 19 , wherein each of the plurality of well electrode structures further includes an electrode trace grouping including a plurality of electrical traces patterned on the top surface and electrically connecting the plurality of vias to the electrode grouping. 
     
     
         24 . The plate of  claim 19 , wherein the plurality of vias are each disposed approximately 0.019 inches outside of the well areas. 
     
     
         25 . The plate of  claim 19 , wherein the plurality of vias includes two vias connecting each of the plurality of electrode contacts with each of the plurality of electrode traces. 
     
     
         26 . The plate of  claim 19 , wherein each of the plurality of electrode contacts includes:
 a first electrically conductive layer extending at least approximately 0.015 inches from a corresponding one of the plurality of vias, and a second electrically conductive layer extending at least approximately 0.0008 inches from the first electrically conductive layer.   
     
     
         27 . The plate of  claim 19 , wherein plurality of electrical traces provide electrical connection between the electrode contact grouping arranged outside of the well area to the electrode grouping arranged inside of the well area. 
     
     
         28 . The plate of  claim 19 , wherein the auxiliary electrode is disposed at an approximate center of the well area, and the working electrodes are arranged in a circle approximately equidistant from the auxiliary electrode. 
     
     
         29 . The plate of  claim 28 , wherein the working electrodes are separated from each other in the circle by a plurality of working electrode spacings and at least one of the plurality of working electrode spacings is sized to permit disposition therein of an auxiliary electrode trace of the plurality of electrode traces connecting the auxiliary electrode to the auxiliary electrode contact. 
     
     
         30 . The plate of  claim 29 , wherein the auxiliary electrode includes a third electrically conductive layer extending at least approximately 0.008 inches past the electrode contact spot corresponding to the auxiliary electrode. 
     
     
         31 . The plate of  claim 29 , wherein the top surface of the substrate further includes a first insulating layer disposed in a pattern that exposes the electrode grouping of each of the plurality of electrode well structures and covers a remainder of the top surface of the substrate. 
     
     
         32 . The plate of  claim 29 , wherein the plurality of working electrode each include a fourth conductive layer disposed over the electrode contact spot associated with a corresponding working electrodes. 
     
     
         33 . The plate of  claim 32 , wherein each of the plurality of working electrodes are disposed at least approximately 0.0014 inches away from the remainder of the plurality of working electrodes. 
     
     
         34 . An electrochemical cell for performing electrochemical analysis, the electrochemical cell being formed on a base plate having a top surface and a bottom surface, the electrochemical cell including:
 a plurality of working electrode zones disposed, and defining a pattern, on the top surface of the base plate; and   at least one auxiliary electrode disposed on the top surface, wherein each of the plurality of working electrode zones are electrically isolated from one another and from the auxiliary electrode   an electrode contact grouping patterned on the bottom surface corresponding to the plurality of working electrode zones and including a plurality of electrode contacts including a plurality of working electrode contacts electrically connected to corresponding working electrode zones and an auxiliary electrode contact electrically connected to the auxiliary electrode, wherein:   the top surface further includes an adhesive layer surrounding the plurality of working electrode zones and defining an adhesive free well area on the top surface,   the working electrode zones are disposed within the well area and the electrode contact grouping is disposed outside of the well area,   the electrochemical cell further includes a plurality of vias electrically connected to the plurality of electrode contacts and passing through the base plate and an electrode trace grouping including a plurality of electrical traces patterned on the top surface and electrically connecting the plurality of vias to the electrode grouping,   the plurality of electrode traces each include:
 a via contact spot in electrical communication with a corresponding one of the plurality of vias outside the well area and extending at least approximately 0.015 inches from a corresponding one of the plurality of vias, an electrical bridge extending from the via contact spot into the well area, 
 an electrode contact spot connected to the electrical bridge inside the well area, 
 a first electrically conductive layer within which each of the plurality of electrode traces is disposed at least approximately 0.013 inches away from a remainder of the plurality of electrode traces 
   a second electrically conductive layer extending at least approximately 0.002 inches beyond the first electrically conductive layer and within which each of the plurality of electrode traces is disposed at least approximately 0.010 inches away from the remainder of the plurality of electrode traces.